🏷️ Basic Information

Make:

Husqvarna

Model:

TE510

Year:

2010

Product Name:

Husqvarna TE510 2010 Service Repair Workshop Manual PDF Download

👋 Introduction

Market Segment:

Dual-sport / Enduro motorcycle, known for its off-road prowess and street legality.

Competitors:

Competes with models from KTM (e.g., EXC series), Yamaha (WR series), Honda (CRF-X series), and Suzuki (DR-Z series) in the off-road and dual-sport segment.

Vehicle Features:

Lightweight chassis, powerful single-cylinder engine, long-travel suspension, capable off-road performance, street-legal equipment.

📋 Manual Details

Systems Covered:

Engine, Fuel System, Ignition System, Cooling System, Lubrication System, Transmission, Clutch, Chassis, Suspension (Front and Rear), Brakes (Front and Rear), Electrical System, Wiring Diagrams, Frame, Bodywork, Troubleshooting, Maintenance, Specifications, Special Tools.

Page Count:

Estimated 300-400 pages (typical for this type of comprehensive manual). Exact page count may vary slightly based on final compilation.

Manual Type:

Service Repair Workshop Manual

Language:

English

Format:

PDF Download

📖 Manual Coverage

Engine:

Detailed breakdown of the single-cylinder, four-stroke engine, including cylinder head, piston, crankshaft, camshaft, valve timing, and assembly/disassembly procedures.

Fuel System:

Carburetor (likely Mikuni or Keihin) specifications, adjustment, cleaning, and troubleshooting; fuel injection system details if applicable for the specific variant.

Ignition System:

CDI ignition system, spark plug specifications, timing adjustments, and troubleshooting of ignition components.

Cooling System:

Radiator, cooling fan, coolant specifications, fluid capacity, and maintenance procedures.

Lubrication System:

Oil pump, oil filter, oil capacity, oil specifications, and lubrication points.

Transmission:

Six-speed gearbox, clutch assembly (hydraulic or cable), gear ratios, lubrication, and repair procedures.

Brakes:

Front and rear disc brake systems, brake pad replacement, caliper service, master cylinder maintenance, brake fluid specifications, and bleeding procedures.

Suspension:

Front telescopic forks (e.g., Marzocchi or WP) and rear monoshock suspension, including oil levels, adjustments, seal replacement, and rebuild procedures.

Electrical System:

Battery specifications, charging system, lighting, starter motor, wiring diagrams for all circuits, and troubleshooting electrical faults.

General Maintenance:

Oil changes, filter replacements, chain adjustment and lubrication, air filter cleaning/replacement, tire pressure checks, and general inspection points.

Engine Repair:

Top-end rebuild (cylinder, piston, rings, valves), bottom-end overhaul (crankshaft, connecting rod), and complete engine disassembly/reassembly.

Transmission Repair:

Clutch replacement, gear inspection and replacement, bearing service, and transmission lubrication.

Suspension Service:

Fork seal replacement, fork oil change and level adjustment, shock absorber service and rebuild.

Brake System Service:

Brake pad replacement, caliper servicing, master cylinder rebuild, brake line replacement, and brake fluid bleeding.

Electrical Troubleshooting:

Diagnostic procedures for electrical issues, component testing, and wiring harness repair.

Chassis And Frame:

Wheel bearing replacement, steering head bearing service, swingarm pivot bearing maintenance, and frame inspection.

Depth:

Comprehensive, covering routine maintenance to complete engine and chassis overhauls. Includes detailed torque specifications, tolerances, and diagnostic flowcharts.

📊 Manual Specifications

File Format:

PDF

Print Quality:

High-resolution, with clear diagrams and text, optimized for digital viewing and printing.

Binding Type:

N/A (Digital Download)

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Engine Type:

Single-cylinder, four-stroke

Displacement:

Approximately 503cc (actual displacement may vary slightly by specific market or sub-model).

Bore X Stroke:

Typically around 98 mm x 66 mm (verify with specific model details).

Compression Ratio:

Likely around 12.0:1 to 13.0:1 (verify).

Valve Train:

SOHC, 4 valves per cylinder

Horsepower:

Estimated 40-50 HP at peak RPM (verify with specific dyno charts or manufacturer specs).

Torque:

Estimated 40-45 Nm at peak RPM (verify).

Carburetion:

Mikuni or Keihin carburetor (e.g., VM41 or FCR41 type) or EFI for specific markets/versions.

Fuel Type:

Unleaded gasoline, octane rating 91 or higher.

🔧 Transmission

Transmission Type:

6-speed manual transmission

Optional Transmission:

N/A (Standard 6-speed)

Clutch Type:

Hydraulic wet multi-plate clutch

Gear Ratios:

Specific gear ratios will be detailed in the manual, crucial for performance tuning.

📐 Dimensions

Length:

Approx. 2200 mm (verify).

Width:

Approx. 800 mm (verify).

Height:

Approx. 1250 mm (verify).

Wheelbase:

Approx. 1470 mm (verify).

Dry Weight:

Approx. 110-120 kg (verify, significant for off-road handling).

Wet Weight:

Approx. 125-135 kg (with fluids, verify).

Front Tire Size:

Typically 90/90-21

Rear Tire Size:

Typically 140/80-18

Wheel Type:

Spoked wheels

Wheel Bolt Pattern:

N/A (Motorcycle specific hub/sprocket arrangement)

🛡️ Safety Features

Safety Ratings:

N/A (Motorcycles are not rated by traditional automotive safety organizations like NHTSA/IIHS).

Braking System:

Hydraulic disc brakes front and rear, providing strong stopping power suitable for off-road and street use.

Lighting:

Headlight, taillight, brake light, turn signals (for street legality).

💡 Technology Features

Infotainment System:

Basic, primarily focused on functional rider aids like odometer, trip meter, and indicator lights. No advanced infotainment systems like touchscreens or GPS.

Assistance Features:

ABS was not standard on most 2010 TE510 models; check specific market specifications. Focus is on rider control and handling.

Connectivity Options:

N/A (No Bluetooth, Wi-Fi, or smartphone integration).

🔧 Maintenance

Oil Change Interval:

Recommended every 1,000-1,500 km or annually (verify specific interval in manual).

Air Filter Cleaning:

Recommended every 500 km or after dusty rides.

Valve Clearance Check:

Typically every 3,000-5,000 km (verify critical interval).

Spark Plug Replacement:

Recommended every 5,000-10,000 km or as needed (verify).

Engine Oil Type:

High-quality synthetic motorcycle oil, SAE 10W-40 or 10W-50, API SG or higher (verify specific viscosity and API rating).

Engine Oil Capacity:

Approx. 1.3 - 1.5 liters (verify with filter change).

Brake Fluid Type:

DOT 4 hydraulic brake fluid.

Coolant Type:

Ethylene glycol-based antifreeze mixture with distilled water (50/50 ratio).

Common Wear Items:

Clutch plates, valve guides, wheel bearings, steering head bearings, fork seals, and chain/sprockets are common wear items on dual-sport bikes.

Electrical Gremlins:

Older European models can sometimes exhibit minor electrical connection issues if not properly maintained or protected from moisture.

Carburetor Tuning:

Carburetor jets and settings may require adjustments based on altitude and rider preference for optimal performance.

📚 Vehicle History

Brand Origin:

Husqvarna Motorcycles is one of the oldest motorcycle manufacturers in the world, founded in Sweden in 1689, initially producing muskets. Motorcycle production began in 1903.

Model Lineage:

The TE series (which stands for 'Todo Terreno' meaning 'All Terrain') has a long history within Husqvarna's off-road motorcycle line. The TE510 specifically has evolved from earlier 500cc enduro models, incorporating technological advancements over the years.

Manufacturing Location:

Husqvarna Motorcycles were manufactured in Huskvarna, Sweden, and later in Italy after acquisition by Cagiva Group. The 2010 models are likely Italian-made.

🏆 Awards & Recognition

Awards And Ratings:

Specific awards for the 2010 TE510 are not widely documented in general reviews; however, Husqvarna's enduro models are generally well-regarded in off-road publications and by riders for their performance and handling characteristics.